Automatic Transmission Unit Disassembly

WARNING: This page is about a different variant/trim than selected.

Reference: AUTOMATIC TRANSMISSION ASSEMBLY DISMOUNTING AND REMOUNTING

CAUTION: If you air-blow a disassembled part near your face, fluid and dust blown away by the compressed air may injure your face, especially your eyes.
When air-blowing, always wear safety goggles and keep your face away from the part to be blown.

NOTE:

Keep component parts in group for each subassembly and avoid mixing them up.
Clean all parts thoroughly with cleaning solvent and air-dry them.
Use kerosene or automatic transmission fluid as cleaning solvent.
Do not use wiping cloths or rags to clean or dry parts.
Check that all oil passages are blown out and are not obstructed.
Check mating surface for irregularities. If irregularities are found, remove them and clean mating surface again.
Soak new clutch discs and brake discs in transmission fluid for at least 2 hours before assembly.
Apply automatic transmission fluid to all O-rings.
When installing seal ring, be careful so that it is not expanded excessively, extruded or caught.
Before installation, be sure to apply automatic transmission fluid to sliding, rolling and thrusting surface of all component parts. Also after installation, be sure to check each part for proper operation.

Extract torque converter (1). And remove oil filler tube and dipstick.
NOTE: Pulling the torque converter out of the transmission at an angle may damage the lip of the oil seal.
Pull the torque converter out of the transmission as straight as possible.

Fig 1: Identifying Torque Converter And Converter Housing
Courtesy of SUZUKI OF AMERICA CORP.
Remove input shaft speed sensor (1) and output shaft speed sensor (2).
Remove 6 adapter case fixing bolts and then remove adapter case (3) and gasket.
NOTE: Remove adapter case straight so as not to cause damage oil seal lip.

Fig 2: Identifying Adapter Case, Input And Output Shaft Speed Sensor
Courtesy of SUZUKI OF AMERICA CORP.
Remove transmission range sensor (1).

Fig 3: Identifying Transmission Range Sensor
Courtesy of SUZUKI OF AMERICA CORP.
Remove C-ring (1) and then remove speed sensor rotor (2).
Remove key.

Fig 4: Identifying Speed Sensor Rotor And C-Ring
Courtesy of SUZUKI OF AMERICA CORP.
Remove oil pump (1) by using special tools.
Special Tool

(A): 09913-65135

(B): 09927-66520

NOTE: Remove oil pump straight so as not to cause damage shaft bushing surface.
Remove bearing at the rear of oil pump (1).
Remove O-ring from oil pump (1).
Holding input shaft (2) by hand, remove converter housing (3).

Fig 5: Removing Oil Pump Using Special Tool
Courtesy of SUZUKI OF AMERICA CORP.
Check dimensions of overdrive (O/D) case (1) surface and clutch cylinder (2) surface for reassembly.
Remove overdrive (O/D) clutch assembly by holding input shaft (3).
Remove O/D case, bearing and bearing race.
NOTE: Confirm direction of bearing and bearing race for reassembly.

Fig 6: Identifying Overdrive Case Surface, Clutch Cylinder And Input Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Remove oil pan (1) and oil pan gasket.
Then remove magnets from oil pan and clean them to steel particles etc.
NOTE:
- Hold oil pan with oil pan side down to prevent foreign material in oil pan from entering valve body.
- If iron powder is found, there is possibility that bearing, gear or clutch plate is worn.
Fig 7: Identifying Oil Pan
Courtesy of SUZUKI OF AMERICA CORP.
Remove oil strainer (1).

Fig 8: Identifying Oil Strainer
Courtesy of SUZUKI OF AMERICA CORP.
Remove overdrive (O/D) brake apply tube (1).
Disconnect connectors, and then remove solenoid wire harness (2).

Fig 9: Identifying Overdrive Brake Apply Tube And Solenoid Wire Harness
Courtesy of SUZUKI OF AMERICA CORP.
Remove valve body (1) mounting bolts as shown in figure.

Fig 10: Identifying Valve Body
Courtesy of SUZUKI OF AMERICA CORP.
Remove accumulator pistons (1) by blowing air into holes (2) as shown in figure.
NOTE: Hold accumulator piston (1) with nylon cloth while blowing air into holes.

Fig 11: Identifying Accumulator Pistons And Holes
Courtesy of SUZUKI OF AMERICA CORP.
Place transmission (1) upright as shown in figure.
NOTE:
- To prevent transmission case from getting damaged, protect its contacting surface with stand by using nylon cloth or the like.
- To facilitate work, use a stand with the size as shown in figure.
Fig 12: Identifying Transmission Placing Position
Courtesy of SUZUKI OF AMERICA CORP.
Check top surface level of forward clutch (2) against case (1) for reassembly.
Remove forward clutch.
NOTE: Confirm direction of bearing and bearing race for reassembly.

Fig 13: Identifying Forward Clutch And Case
Courtesy of SUZUKI OF AMERICA CORP.
Remove direct clutch (1).

Fig 14: Identifying Direct Clutch
Courtesy of SUZUKI OF AMERICA CORP.
Remove pawl bracket (1), and then parking lock rod (2) from manual shift lever.
Remove pawl spring (3), pawl pin and parking lock pawl (4).

Fig 15: Identifying Parking Lock Rod, Pawl, Pawl Bracket And Spring
Courtesy of SUZUKI OF AMERICA CORP.
Remove 2 bolts (1) from valve body side.

Fig 16: Identifying Valve Body Side Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Remove center support assembly (1).

Fig 17: Identifying Center Support Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Remove retaining ring (1), planetary gear assembly leaf spring, bearing and bearing race.
NOTE:
- Be careful not to cause damage to case when removing retaining ring.
- Confirm direction of bearing and bearing race for reassembly.
Fig 18: Identifying Retaining Ring
Courtesy of SUZUKI OF AMERICA CORP.
Remove apply tube.
Remove reverse brake return spring (1) using special tools.
Special Tool

(A): 09941-84510

(B): 09926-98320

Fig 19: Removing Reverse Brake Return Spring Using Special Tools
Courtesy of SUZUKI OF AMERICA CORP.
Remove reverse brake piston (1) by applying compressed air (400 - 800 kPa, 4 - 8 kgf/cm² , 57 - 113 psi) to oil hole (2).

Fig 20: Removing Reverse Brake Piston Using Compressed Air
Courtesy of SUZUKI OF AMERICA CORP.
Apply compressed air (400 - 800 kPa, 4 - 8 kgf/cm² , 57 - 113 psi) to oil hole (3) to remove brake reaction sleeve (1) and secondary reverse piston (2).
Remove brake reaction sleeve (1) and secondary reverse piston (2) by using special tools.
Special Tool

(A): 09920-20310

Fig 21: Removing Brake Reaction Sleeve And Secondary Reverse Piston Using Special Tools
Courtesy of SUZUKI OF AMERICA CORP.
Remove manual shift shaft and lever as follows.
1. Undo caulking of sleeve cover (1) by using flat end rod or the like and hammer.
  
  Fig 22: Removing Sleeve Cover Using Flat End Rod
  Courtesy of SUZUKI OF AMERICA CORP.
2. Drive out manual shift lever pin (1) by using special tool and hammer.
  Special Tool
  
  (A): 09922-89810
3. Pull out manual shift shaft (2) from transmission case, and then remove manual shift lever (3) and sleeve cover (4).
  
  Fig 23: Removing Manual Shift Lever Pin Using Special Tool And Hammer
  Courtesy of SUZUKI OF AMERICA CORP.
Remove oil seal (1) from both sides of transmission case.

Fig 24: Removing Oil Seal From Transmission Case Using Tool
Courtesy of SUZUKI OF AMERICA CORP.
Remove cover plate (1).

Fig 25: Identifying Cover Plate
Courtesy of SUZUKI OF AMERICA CORP.